Shoemaking method



F. MACCARQNE ET A1. y 2,041,360

SHOEMAKING METHD y Filed March 50, 1935 3 Sheets-Sheet 1 INVENTORS Fred Macarro/1e ATTRNEYS lVlifly l9, 1936- F. MAccARoNE -r Al. 2,041,360

SHOEMAKING METHOD Filed March 50," 1955 5 Sheets-Sheet? mx* ATTO NEYS.

May 19, 1936.

Filed March 50, 1935 3 Sheets-Sheet 3 @Lg-ZZ.

4Patented ay 19, 1936 STATES PATENT OFFICE lyn,

N. Y., assignors to The Del-Mac Shoe Process Corporation, New York, N. Y.

Application March 30, 1935, Serial No. 13,873

y 11 Claims.

.Our invention relates to shoes and shoe making, and particularly to methods of making shoes in which the insole and outsole components are divisions of a common blank, and the insole isy channeled to provide a channel leaf for stitch lasting or an integral lip or rib whereby the shoe upper may be side lasted in relation to the insole.

Heretofore, where the blank has been divided to obtain an insole and an outsole of proper weights for the finished shoe, it has been found that the insole member was so light as to require the exercise of great care and skill in properly performing the subsequent channel cutting operation, and this has been found particularly true where the insole division of the blank is skeletonized over the forepart, and therefore weaker and less capable of standing up under the subsequent channeling operation. Because of this, it has been usual to divide the blank so as to obtain an insole substantially heavier than is necessary or desirable for the nished shoe, and the outsole has thereby been unduly reduced in weight.

The principal object of our invention, therefore, is to provide an improved method in accordance with which the insole is dened and channeled in a full weighted sole blank before the blank is divided into insole and outsole parts, each part having proper proportionate weight for the lnished shoe.

Another principal object is to provide an improved method having the foregoing advantages in which the insole channel leaves, integral lip or rib members, may be positioned in relation to the edge of an insole predened and preformed in the` full weighted sole blank.

A further object is to provide an improved method having the foregoing advantages which may be practiced by the use of conventional shoe making machinery, and other and further objects will appear from the following specification.

Referring to the drawings:

Figure 1 is a plan view of a rounded sole blank having an incision formed therein to define the contour of an insole.

Figure 2 is -a cross sectional View taken on line 2 2 of Fig. 1.

Figure 3 is a sectional view similar to Fig. 2 showing the channel cuts formed in the blank and the waste portionremoved in the course of the channeling operation.

Figure 4 is a sectional view illustrating the manner in which the blank is divided to provide the properly sized and channeled insole member and an outsole member.

Figure 5 is a plan view of the insole member showing the channel leaves erected and secured together to form a lip.

Figure 6 is a cross sectional view taken on line 9-5 of Fig. 5.

Figure 7 is a plan view of the outsole member. 5

Figure 8 is a plan view of a sole blank similar to the blank shown in Fig. 1, in which the insole member has been defined and initially formed by the removal of a triangular rand.

Figure 9 is a cross sectional view taken on line V10 9--9 of Fig. 8 and shows the rand removed in preforming the insole and the condition of the sole blank after such removal.

Figure 10 is a cross sectional View similar to Fig. 9 and illustrates the blank having the channel 15 cuts formed therein.

Figure 11 is a cross sectional View illustrating the manner in which the blank may -be divided to obtain a fully formed and channeled insole having an aperture in the ball portion thereof, 2@ and an outsole member having a projection at its ball portion adapted to register with the insole aperture.

Figure 12 is a plan view of the insole member shown in Fig. 11 after the channel leaves have 25 been erected to `forni a lip.

Figure 13 is a cross sectional view of the insole taken on line l-l of Fig. 12.

Figure 14 is a plan view'of the outsole member shown in Fig. 11.

2@ indicates a full weighted sole blank having a thickness corresponding to the combined thickness of the desired insole and outsole and rounded to the configuration of an outsole. The blank has a cut or incision, 2i, formed therein which defines the coniiguration of the desired 4insole and extends inwardly from a face of the blank a distance corresponding to the thickness of thedesired insole. The cut or incision, 2l, may be formed in the blank in accordance with the method taught in United States Patents #1,988,282 and #1,988,283, issued to applicant,Fred Maccarone, January 15, 1935, but more preferably `as taught in the pending application of said Fred Maccarone, Serial No. 711,673, filed February 17, 1934.

Channel cuts, 22 and 23, are then formed in the blank in the usual manner and by means ol' the usual equipment, the channel cut, 23, extending angularly from the same surface of the blank as does the incision, 2l, and spaced inwardly from said incision as illustrated. The channel cut, 22, intersects the incision, 2l, and is, of course, parallel with the out, 23. In the course of this channel cutting operation, a light marginal waste rand, 2d, is removed, said rand com- 56 prising material lying outwardly of the incision, 2|, and channel leaves, 25 and 26, are dened, as will be readily understood.

The sole blank thus prepared is then split within the depth of the incision, 2|, along line of Fig. 3 to divide the blank into a separate outsole portion, 21, and a properly sized insole portion, 28, carrying the integral channel leaves or ylip members, and 2S, respectively. In the make shoes with side-lasting methods in which an integral lip or rib member is required, the

members, 25 and 26, are erected and adhesively 4 secured together to provide the desired lip, 3U,

-as shown in Figs. 5 and 6, to which the upper may be stapled or otherwise secured. Where the the insole and the lip by meansv of a flanged layer of properly shaped fabric (not shown) in accordance with the popular economy method.

We desire to point out here that although we prefer to'dene the edge of the insole by forming the cut, 2|, in the full weighted sole blank, this step is not absolutely essential to our invention, broadly considered, and the split-oif insole, 28, may be rounded or otherwise trimmed to size after the sole blank has been divided into/the insole and outsole parts. However, such an operation would be attended by diiliculties because such subsequent insole rounding operation would have to be performed in relation to the channel cuts, 22 and 23, and, as the use of the usual rounding machine requires that the sole member be clamped between patterns, it would be diicult to properly position the insole inthe machine so that the patterns lwill bear proper relation to the allel.

channel cuts.

The method practiced as above described will be found to produce satisfactory sole members in all cases where the edge of the outsole and the edge of the smaller insole member are par- However, it often happens that the edge contour of the insole diiers materially from the contour of the outsole edge, and Where that isl the case, it is not practical to space the channel lcuts, 22 and 23, in relation to the outsole rounded edge of the blank. To meet this situation, we

have provided amodification of our method in accordance with which we define the insole edge by an incision or cut, 2|', which defines and forms the edge of the insole member, and also an angular cut, 3|, which extends from the face of the blank inwardly and meets the cutor incisin, 2|', at a. point at or just-above the bottom of said incision.

The cuts, 2| and 3|, may be made with one pending application of Fred Maccarone, Serial No. 711,673, above referred to.

The making of the cuts, 2| and 3|, results in a rand-like waste portion, 32, and the formation of a notch-shaped groove, 33, the inner Wall of 5 which forms the edge, 35, of the insole, 34. The full Weighted blank is then channeled in the same manner and by the same means as above described except that the position of the channel cuts, 22 and 23', may be gauged from the insole edge, 35, instead of from the outsole rounded edge of the blank. The blank thus prepared may then be divided as previously described to obtain an imperforate insole member.

We have found that there is distinct advantage in positioning the inclined cut, 3| inwardly of the edge of the sole blank so that the edge thickness of the blank is not reduced, thus facilitating proper splitting at the marginal portions of the blank when the blank is divided into insole and outsole parts by the preferred method of splitting.

We have illustrated in Fig. 11 how the sole blank may be divided along line :v -:v of Fig. 10 to obtain an outsole, 36, centrally elevated in thickness over the central area oi its ball portion, and a perfectly sizedand channeled insole having an opening in the ball portion thereof corresponding to said Outsole elevation, the margins of the elevatedfarea of the outsole being beveled on a long angle. this manner, we prefer to follow the principles taught in United States Patent #1,988,231-, granted to Fred Maccarone January 15, 1935, wherein a method is disclosed in accordance with which a sole blank, having a thickness. equal to the 35 combined thickness of the insole and outsole desired, is temporarily distorted by inexing or depressing it over areas corresponding to the skeletonized portions of the desired insole so that such portions willavoid the blade of a 40 splitting machine byfmeans of which the blank is divided. However, we are aware that there are other methods of dividing the blank -to obtain sole members of substantiallythe saine construction if for any reason it may be desired to prac- 40 tice such other methods.

The insole, 34, may be employed for stitchlasted shoes, or the leaf members, 25' and 26', may be erected and cemented together to form a lip, 30', for side-lasting methods similarly as the insole, 28.

'After the upper has been lasted and secured to the insole and such further operations as may be necessary preparatory to laying the outsole have been performed, an outsole is secured in proper relation to' the insole member by stitching or cementing to the overlasted portions of the vupper and to the insole,`and where a welted construction is desired, to the outwardly extending portions of a welt. Our method lends itself very Well to the production of welt shoes, the welt being secured to the insole lip in accordance with common practices which form no part of this invention, and which we have not deemed it necessary to describe. v

It will be apparent that because the channel cuts extend inwardly from a surface of the full weighted blank, and because the insole is bottomed on the last with its channeled surface outward, that when the outsole is laid and assembled, the facing surfaces of the insole and outsole will not be the divided surfaces of the blank. However, inasmuch as shoes are made in mated pairs, it will be apparent that the in- Y sole obtained from the blank rounded for the 75 In dividing the sole blank in 30 assises right foot will be used for making the lett shoe, and vice versa.

lt might appear from the drawings, which are greatly exaggerated for the purposes of this disclosure, that some diculty would be experienced in carrying out this practice where the construction embodies the skeleton insole, 35i. I-iowever, the beveled margins, d, of the insole opening are in fact very light and dexible and readily take the position indicated in dotted lines of `Fig. i3, whereby they are adapted to meet ush with the beveled shores of the island-like outsole elevation so smoothly that it is difficult to discover by simple observation on which side or^ the insole the bevel is formed, with the result that the interior of the nished shoe is so smooth and flush as to be indistinguishable :from shoes in which the divided portions of the same sole blank are assembled together.

Having thus described our invention, we claim:

1. In shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes forming a channel leaf integral with the insole portion of the blank and then dividing the blank.

2. in shoe making methods, that improvement which includes providing a rounded outsole blank having an inward cut therein defining the edge of an insole, said cut extending to a depth corresponding to the thickness of a desired insole, then channeling the insole portion of the blank, and thereafter dividing the blank within the depth of said cut to obtain an outsole and a properly sized and channeled insole.

3. In shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes forming a cut in the blank to define the edge of the desired insole, channeling the blank in relation to the insole edge thus defined, and then dividing the blank.

4. In shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes forming a cut in the blank to denne the edge of the desired insole, said cut extending to a depth corresponding to the thickness of the insole desired, channeling the insole portion of the blank in relation to the insole edge thus defined, and dividing the blank within the depth o said cut to obtain an outsole and a properly sized and channeled insole.

5.111 shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes forming a groove in the blank said groove extending to a depth corresponding to the thickness of the insole desired and having a wall thereof defining 'the desired insole edge, channeling the insole portion of the blank in relation to said wall, and dividing .the blank Within the depth of said groove to obtain an outsole and a properly sized and channeled insole.

6. In shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes forming a channel leaf integral with the insole portion of the blank before it is divided, dividing the blank into insole and outsole portions, and erecting said channel leaf to form a lip whereby the upper of the shoe may be attached.

7. In shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes providing a rounded sole blank having an inward cut therein defining the edge of an insole, said cut extending to a depth corresponding to the thickness of the desired insole, forming a channel leaf integral with the insole portion of said blank, and dividing the blank within the depth of said cut to obtain a properly sized insole having said leaf integral therewith.

8. In shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes providing a rounded sole blank having an inward cut therein deiining the edge of an insole, said cut extending to a depth corresponding to the thickness of the desired insole, forming a channel leaf integral with the insole portion of said blank, dividing the blank within the depth of said cut to obtain a properly sized insole having said leaf integral therewith, and erecting said leaf to provide a lip whereby the upper of the shoe may be attached.

9. In shoe making methods wherein a sole blank is divided to obtain an insole and an outsole, that improvement which includes forming a groove in the blank to define an insole, the inner wall of said groove forming the edge of the insole desired, forming a channel leaf in the insole portion of the blank inwardly of said groove and gauged in relation to said wall and thereafter dividing the blank in a plane within the depth of the groove to obtain an outsole and a properly sized insole, said insole having an integral channel leaf carried thereby.

10. In shoe making methods wherein a sole blank is divided to obtain an insole having an opening in its forepart and an outsole having a projection corresponding to said insole opening, that improvement which includes forming a cut in the blank, to dene the edge of the desired insole, said cut extending to a depth corresponding to the thickness of the insole desired, channeling the insole portion ofthe blank in relation to the insole edge thus dened, and dividing the blank within the depth of said cut to obtain an outsole and a properly sized and channeled insole.

11. In shoe making methods wherein a sole blank is divided to obtain a skeletonized insole and a complemental outsole, that improvement which includes channeling the insole portion of the blank, and dividing the blank to obtain an` outsole having a projection thereon and a chan-1 neled insole having an opening therein to receive said projection, said insole and outsole being counterparts.

FRED MACCARONE. HARRY L. SUTCLEFE. 

